Ever-Power Worm Gear Reducer
High-efficiency, high-strength double-enveloping worm reducer
Overview
Technical Info
Low friction coefficient upon the gearing for high efficiency.
Powered by long-long lasting worm gears.
Minimal speed fluctuation with low noise and low vibration.
Lightweight and compact in accordance with its high load capacity.
The structural strength of our cast iron, Heavy-duty Correct angle (HdR) series worm gearbox is due to how we dual up the bearings on the input shaft. HdR series reducers can be found in speed ratios which range from 5:1 to 60:1 with imperial center distances ranging from 1.33 to 3.25 inches. Also, our gearboxes are given a brass springtime loaded breather connect and come pre-filled with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A FAR MORE AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have already been the go-to answer for right-angle power tranny for generations. Touted for his or her low-cost and robust building, worm reducers could be
found in almost every industrial setting requiring this type of transmission. However, they are inefficient at slower speeds and higher reductions, produce a lot of heat, take up a lot of space, and require regular maintenance.
Fortunately, there is an alternative to worm gear pieces: the hypoid gear. Typically used in auto applications, gearmotor businesses have begun integrating hypoid gearing into right-angle gearmotors to solve the issues that arise with worm reducers. Available in smaller general sizes and higher decrease potential, hypoid gearmotors have a broader selection of possible uses than their worm counterparts. This not merely enables heavier torque loads to end up being transferred at higher efficiencies, nonetheless it opens options for applications where space is a limiting factor. They can sometimes be costlier, but the savings in efficiency and maintenance are really worth it.
The following analysis is targeted towards engineers specifying worm gearmotors in the range of 1/50 to 3 horsepower, and in applications where speed and torque are controlled.
How do Worm Gears and Hypoid Gears Differ?
In a worm gear established there are two components: the input worm, and the output worm gear. The worm can be a screw-like gear, that rotates perpendicular to its corresponding worm equipment (Figure 1). For instance, in a worm gearbox with a 5:1 ratio, the worm will comprehensive five revolutions as the output worm equipment will only complete one. With an increased ratio, for example 60:1, the worm will finish 60 revolutions per one result revolution. It is this fundamental arrangement that triggers the inefficiencies in worm reducers.
Worm Gear Set
To rotate the worm equipment, the worm only encounters sliding friction. There is absolutely no rolling component to the tooth contact (Determine 2).
Sliding Friction
In high reduction applications, such as for example 60:1, you will see a sizable amount of sliding friction because of the lot of input revolutions necessary to spin the output gear once. Low input rate applications have problems with the same friction problem, but for a different reason. Since there exists a large amount of tooth contact, the original energy to begin rotation is higher than that of a comparable hypoid reducer. When driven at low speeds, the worm needs more energy to keep its movement along the worm gear, and lots of that energy is dropped to friction.
Hypoid versus. Worm Gears: A FAR MORE AFFORDABLE Right-Angle Reducer
However, hypoid gear sets consist of the input hypoid gear, and the output hypoid bevel equipment (Figure 3).
Hypoid Gear Set
The hypoid gear established is a hybrid of bevel and worm gear technologies. They encounter friction losses due to the meshing of the apparatus teeth, with minimal sliding included. These losses are minimized using the hypoid tooth pattern that allows torque to end up being transferred easily and evenly across the interfacing areas. This is what gives the hypoid reducer a mechanical benefit over worm reducers.
How Much Does Efficiency Actually Differ?
One of the biggest problems posed by worm gear sets is their insufficient efficiency, chiefly in high reductions and low speeds. Typical efficiencies can vary from 40% to 85% for ratios of 60:1 to 10:1 respectively. Conversely, hypoid gear sets are usually 95% to 99% efficient (Figure 4).
Worm vs Hypoid Efficiency
“Break-In” Period
Regarding worm gear sets, they do not run at peak efficiency until a specific “break-in” period has occurred. Worms are usually made of steel, with the worm gear being made of bronze. Since bronze is certainly a softer steel it is proficient at absorbing large shock loads but will not operate efficiently until it’s been work-hardened. The high temperature generated from the friction of regular working conditions really helps to harden the top of worm gear.
With hypoid gear pieces, there is absolutely no “break-in” period; they are usually made from steel which has recently been carbonitride warmth treated. This allows the drive to use at peak efficiency as soon as it is installed.
Why is Efficiency Important?
Efficiency is among the most important things to consider when choosing a gearmotor. Since most employ a long service lifestyle, choosing a high-efficiency reducer will reduce costs related to procedure and maintenance for years to come. Additionally, a far more efficient reducer allows for better reduction ability and use of a motor that
consumes less electrical energy. One stage worm reducers are typically limited by ratios of 5:1 to 60:1, while hypoid gears possess a decrease potential of 5:1 up to 120:1. Typically, hypoid gears themselves only go up to reduction ratios of 10:1, and the additional reduction is provided by another type of gearing, such as helical.
Minimizing Costs
Hypoid drives can have an increased upfront cost than worm drives. This could be attributed to the excess processing techniques required to create hypoid gearing such as for example machining, heat treatment, and special grinding methods. Additionally, hypoid gearboxes typically utilize grease with intense pressure additives rather than oil which will incur higher costs. This cost difference is composed for over the duration of the gearmotor due to increased performance and reduced maintenance.
A higher efficiency hypoid reducer will ultimately waste less energy and maximize the energy getting transferred from the Gearbox Worm Drive electric motor to the driven shaft. Friction is certainly wasted energy that takes the form of heat. Since worm gears generate more friction they run much hotter. In many cases, using a hypoid reducer eliminates the need for cooling fins on the engine casing, further reducing maintenance costs that might be required to keep the fins clean and dissipating heat properly. A comparison of motor surface temperature between worm and hypoid gearmotors can be found in Figure 5.
In testing the two gearmotors had equally sized motors and carried the same load; the worm gearmotor produced 133 in-lb of torque as the hypoid gearmotor produced 204 in-lb of torque. This difference in torque is due to the inefficiencies of the worm reducer. The electric motor surface area temperature of both units began at 68°F, space temperature. After 100 a few minutes of operating time, the temperature of both products began to level off, concluding the check. The difference in temperature at this stage was considerable: the worm unit reached a surface temperature of 151.4°F, while the hypoid unit only reached 125.0°F. A difference around 26.4°F. Despite being run by the same electric motor, the worm device not only produced much less torque, but also wasted more energy. Important thing, this can result in a much heftier electrical costs for worm users.
As previously mentioned and proven, worm reducers run much hotter than equivalently rated hypoid reducers. This decreases the service life of the drives by placing extra thermal stress on the lubrication, bearings, seals, and gears. After long-term contact with high heat, these elements can fail, and essential oil changes are imminent because of lubrication degradation.
Since hypoid reducers run cooler, there is little to no maintenance required to keep them operating at peak performance. Oil lubrication is not needed: the cooling potential of grease is enough to ensure the reducer will run effectively. This eliminates the necessity for breather holes and any mounting constraints posed by oil lubricated systems. It is also not necessary to replace lubricant because the grease is meant to last the life time usage of the gearmotor, getting rid of downtime and increasing efficiency.
More Power in a Smaller Package
Smaller motors can be utilized in hypoid gearmotors due to the more efficient transfer of energy through the gearbox. In some instances, a 1 horsepower engine generating a worm reducer can produce the same result as a comparable 1/2 horsepower motor generating a hypoid reducer. In a single study by Nissei Company, both a worm and hypoid reducer had been compared for use on an equivalent application. This 
study fixed the reduction ratio of both gearboxes to 60:1 and compared motor power and result torque as it related to power drawn. The study concluded that a 1/2 HP hypoid gearmotor can be utilized to provide similar efficiency to a 1 HP worm gearmotor, at a fraction of the electrical cost. A final result displaying a evaluation of torque and power intake was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in electric motor size, comes the advantage to use these drives in more applications where space is a constraint. Because of the method the axes of the gears intersect, worm gears consider up more space than hypoid gears (Body 7).
Worm vs Hypoid Axes
Coupled with the ability to use a smaller motor, the entire footprint of the hypoid gearmotor is a lot smaller sized than that of a similar worm gearmotor. This also helps make working environments safer since smaller sized gearmotors pose a lesser threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors can be they are symmetrical along their centerline (Shape 9). Worm gearmotors are asymmetrical and result in machines that are not as aesthetically satisfying and limit the amount of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of the same power, hypoid drives significantly outperform their worm counterparts. One essential requirement to consider can be that hypoid reducers can move loads from a lifeless stop with more ease than worm reducers (Physique 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer substantially more torque than worm gearmotors over a 30:1 ratio because of their higher efficiency (Figure 11).
Worm vs Hypoid Result Torque
Both comparisons, of allowable inertia and torque produced, were performed using equally sized motors with both hypoid and worm reducers. The results in both research are obvious: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As proven throughout, the benefits of hypoid reducers speak for themselves. Their style allows them to run more efficiently, cooler, and provide higher reduction ratios in comparison with worm reducers. As tested using the studies presented throughout, hypoid gearmotors are designed for higher initial inertia loads and transfer more torque with a smaller sized motor than a comparable worm gearmotor.
This can result in upfront savings by allowing the user to buy a smaller motor, and long-term savings in electrical and maintenance costs.
This also allows hypoid gearmotors to be a much better option in space-constrained applications. As proven, the overall footprint and symmetric style of hypoid gearmotors makes for a far more aesthetically pleasing design while improving workplace safety; with smaller, less cumbersome gearmotors there exists a smaller potential for interference with workers or machinery. Clearly, hypoid gearmotors are the most suitable choice for long-term cost benefits and reliability in comparison to worm gearmotors.
Brother Gearmotors offers a family group of gearmotors that enhance operational efficiencies and reduce maintenance needs and downtime. They offer premium efficiency models for long-term energy financial savings. Besides being extremely efficient, its hypoid/helical gearmotors are small in proportions and sealed forever. They are light, dependable, and provide high torque at low quickness unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality finish that assures regularly tough, water-restricted, chemically resistant systems that withstand harsh circumstances. These gearmotors likewise have multiple regular specifications, options, and mounting positions to make sure compatibility.
Specifications
Material: 7005 aluminum gear box, SAE 841 bronze worm gear, 303/304 stainless steel worm
Weight: 105.5 g per gear box
Size: 64 mm x 32 mm x 32 mm
Thickness: 2 mm
Gear Ratios: 4:1
Take note: The helical spur equipment attaches to 4.7 mm D-shaft diameter. The worm gear attaches to 6 mm or 4.7 mm D-shaft diameters.
Worm Gear Quickness Reducers is rated 5.0 out of 5 by 1.
8 Ratios Available from 5:1 to 60:1
7 Gear Box Sizes from 1.33 to 3.25″
Universally Interchangeable Style for OEM Replacement
Double Bearings Used on Both Shaft Ends
Anti-Rust Primer Applied Inside and Outside Gearbox
Shaft Sleeve Protects All Shafts
S45C Carbon Metal Shafts
Flange Mount Versions for 56C and 145TC Motors
Ever-Power A/S offers an extremely wide variety of worm gearboxes. Due to the modular design the standard program comprises countless combinations when it comes to selection of gear housings, mounting and connection choices, flanges, shaft designs, kind of oil, surface treatments etc.
Sturdy and reliable
The look of the EP worm gearbox is easy and well proven. We just use high quality components such as houses in cast iron, aluminium and stainless steel, worms in case hardened and polished steel and worm wheels in high-quality bronze of particular alloys ensuring the maximum wearability. The seals of the worm gearbox are provided with a dust lip which efficiently resists dust and water. Furthermore, the gearboxes are greased for life with synthetic oil.
Large reduction 100:1 in a single step
As default the worm gearboxes allow for reductions of up to 100:1 in one step or 10.000:1 in a double decrease. An comparative gearing with the same gear ratios and the same transferred power is bigger than a worm gearing. Meanwhile, the worm gearbox is in a far more simple design.
A double reduction could be composed of 2 regular gearboxes or as a special gearbox.
Worm gearbox
Ratios
Maximum output torque
[Nm]
Housing design
Series 35
5:1 – 90:1
25
Aluminium
Series 42
5:1 – 75:1
50
Cast iron
Series 52
7:1 – 60:1
130
Cast iron
Series 61
7:1 – 100:1
200
Cast iron
Series 79
7:1 – 60:1
300
Cast iron
Series 99
7:1 – 100:1
890
Cast iron
Other product benefits of worm gearboxes in the EP-Series:
Compact design
Compact design is among the key words of the standard gearboxes of the EP-Series. Further optimisation can be achieved by using adapted gearboxes or unique gearboxes.
Low noise
Our worm gearboxes and actuators are extremely quiet. This is because of the very easy running of the worm gear combined with the utilization of cast iron and high precision on component manufacturing and assembly. In connection with our precision gearboxes, we take extra treatment of any sound that can be interpreted as a murmur from the gear. Therefore the general noise degree of our gearbox is reduced to a complete minimum.
Angle gearboxes
On the worm gearbox the input shaft and output shaft are perpendicular to one another. This often proves to become a decisive advantage producing the incorporation of the gearbox significantly simpler and more compact.The worm gearbox is an angle gear. This is often an advantage for incorporation into constructions.
Strong bearings in solid housing
The output shaft of the EP worm gearbox is very firmly embedded in the apparatus house and is ideal for immediate suspension for wheels, movable arms and other areas rather than needing to create a separate suspension.
Self locking
For larger equipment ratios, Ever-Power worm gearboxes will provide a self-locking impact, which in lots of situations can be utilized as brake or as extra security. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them well suited for a wide variety of solutions.
